Preparation of piled webs



Oct. 24, 1950 H. GMBEL 2526 649 PREPARATION OF PILED WEBS Filed' Nov; 15, 1946 Patented Oct. 24, 1950 UNITED STATES PATENT OFFICE .H--,2',52-6,649 t PR P RA'r ofi'oF PILED WEBS Hyman Gerber, Chicago, 111. Applieation. ev'eeflierfia194s, Serial No. 709, 19.9

6 Claims-# ('01. 154-47) This invention relates to thepreparation of piled webs and the like. 'Theinve'ntion is par ticularly useful in the manufacture of "plastic products constituting artificial fur-,rugs, tasse'ls; and other forms of trimming; together'withmany other products having-thecharacteristics of a flexible web vto which are integrally attached filaments, etc.

An'object of the invention is to providea piled flexible web; suitable for uses-to whichfurs are put and for other uses, such'as rugs, trimming,

etc; Yet another object is to provide a novel Ti method of preparation of such products whereby a web of the desired flexibility maybe prepared while at the same time forming integrally therewith filaments or monofils, as well as inultifils. Yet another object'is' to provide anew type" of product havingthe characteristics of skin, hair,

or -fur,'and the pliability desired forrugs, tassels,

andother like products, while providing a simple methodfor accurately and expeditiously forming the product in large sheets of a predetermined shape and character. A further object is to provide a product of the character above described fromplastic material which may be readily washed in soap and'w'ater and kept in hygienic condition, while at the -sametime providing the advantages-that flow from'such products as fur, fur peltries, rugs, velvets, plushes, trimmings, and similar products. Other specific objects and advantages will appear as the specification proceeds.

tion of the flexible web and filaments resulting from the; cutting and fusing operation illustrated in Fig. 6; and Fig. 8, a perspective View of the piled web structure secured to a backing offabric or other material:

strument 8 through which current is supplied to two electrical conductors Ill and H,

the elements 6 and T.- ,The regulating instru-. ment is connected to an electric source 9 by the When an electric current is sent through the circuitincorporating. the regulating instrument 8 and-the,;high"resistance wire I, the temperature of the -;high-. resistancewire will rise. in direct proportion to the strengthyof the current sent through: it. Its lengthalsc will increase indirect"v roportion; and-it must, therefore, be adjusted The invention is illustrated; in a preferred em-- bodiment, by the accompanying drawing, in Which Figure l is a-diagrammatic plan view of ap \paratus that may be employed; Fig. 2, a perspective view of a bundle of filaments which may be subjected to the process described; Fig. 3, a sideview in elevation of the structure shown in Fig. 2,

illustrated in the process of being severed through the action of a heated body; Fig. 4, a side view in elevation'of the resulting web and'a portion of I the filaments formed integrally therewith; Fig. 5, a perspective view of a flexible web with filato provide the desired tautness at the finally selected temperature found satisfactory.

To make a fur pelt of heat-fused thermoplatic piled sheet, the thermoplastic fibers to be used, which may be either-filaments or spun threads, are presented to the'high resistance Wire I in any suitable manner, enabling the wire to provide a fusion of the filaments along at least one end of the; fil aments. This may be" done by bringing the wire or any other heated body along the endsof the filaments arranged in a compact manner;

or, asillustrated-in Figs. ,1, 2. and 3, the bound filamentsfrnay be brought into contact at. an I intermediate point withthe';wire I so as to cut throughrthe filaments. ln this form of the invention, the filaments are clamped within the binders 2s0 as to provide a compact and aligned ments extending from opposite sidesthereof; Fig;

6, a :broken view of the apparatus shown in Fig.

1 but illustrating the bundle'of filaments sup-'- ported for engagement, withthe cutting wire at' at a difierent angle; Fig. 7, aside view in elevaarrangementof the filaments. It will be understood-that any-suitabletype of clamping means for maintaining the filaments in the desired hipeiandarrangement may be employed. The

F chief: purposeof the'clamping operation is not to compress the fibers. but,;:rather;.to-. orient them,'fa 52- (1) The polyamides (generally recognized under the name nylon) (2) Vinylidene chloride (3) The copolymers, such as vinylidene chloridevinyl chloride 01 H or H [-o o-o o 01 H H H or vinyl chloride-vinyl acetate (4) The cellulose derivatives, such as cellulose acetate The bundle of fibers I3 is brought to bear transversely upon the hot resistance wire, as illustrated in Figs. 1 and 3, and the portions of the fibers or filaments adjacent the wire soften and melt, forming a thin flexible web. In the severing operation, the wire will pass through the first layer of fibers, will then melt the second layer, and so on. In the meantime, the sections of the thermoplastic fibers which have been thus severed by a hot wire, once past contact, will resolidify. Fig. 3 is a bottom plan view of the fiber bundle and shows the wire partially having passed through the fibers. f The resulting product is illustrated in Fig. 4, which represents one-half of the fiber bundle as shown being divided in Fig. 4.

The fibers I! of the bundle I3, after being severed and having their inner ends fused into a sheet, now become the filaments [8 of the structure shown in Fig. 4. Here, the fused ends of the filaments provide the flexible web IS. The web or substratum I 9 is thus formed upon resolidification of the flowing material and provides a thermoplastic film integral with the fibers.

I have found that high efliciency is attained in this process when the fiber bundle is moved along the hot resistance wire, as indicated by the arrows 25 and 2| in Fig. 1. This permits the excess material fiow to be left behind on the hot wire, and also insures that the heat absorbed by the thermoplastic in fusion will not cool the wire through the length of contact.

As the bundle is moved down the wire, under this desired method, it should be pressed firmly against it, as is indicated by the arrows 22 and 23 in Fig. 3. Also, I prefer to apply force in'the direction of the arrows 24 and 25 in Fig. 3 to character.

keep apart the two thermoplastic sheets 19 as they are being formed, so that they do not fuse with one another.

Under certain circumstances, it may be desired to have the two plastic sheets 19 fused together so as to form :a plastic web of the type shown in Fig. 5, having filaments extendin from opposite sides thereof. In this operation, the two sheets L! are pressed together and a fusion is formed, with a single plastic Web 26 being formed, as illustrated in Fig. 5. The filaments 21 extend from the opposite sides thereof.

In the making of certain types of fur peltries, it is" desired to have the filaments emerge at an oblique angle from the base sheet or web, and this is accomplished by presenting the fiber or filament bundle to the hot wire I, as illustrated best in Fig. 6. The filament bundle l3, being presented to the wire at an angle as illustrated in Fig. 6, forms a thermoplastic skin 28 from which the filaments 29 emerge at an angle, as in many fur pelts. This is illustrated in the greatly enlarged view of Fig. 7.

While the heat-fused thermoplastic piled web may be usedas such in many products, it will be understood that for many uses it should be attached to a backing material. In Fig. 8, the piled Web [9' is shown secured by cement 30 to the fabric or other backing 3i.

Operation In the operation of the process, the filaments or fibers, preferably of -a thermoplastic type, are united by fusing a portion of an aligned group of fibers so that the fused material forms a thin plastic skin or web integrally uniting the fibers.

When the fibers are thermoplastic, they may be brought into an aligned position by the clamping means I2 or by any other holder and drawn along the heated wire I to sever the bundle, as illustrated in Fig. 3. By drawing the lower portion of the bundle apart as the severance is accomplished, there are provided two Webs l9, each having filaments attached thereto. If the members l9 are pushedtogether immediately after the severance, a structure such as shown in Fig. 5 is produced.

In the severing and solidification steps, it is important that the timing be such that the fused ends of the fibers form a continuous web or sheet and a sheet which is preferably highly flexible in By drawing the bundle [3 along the hot wire I, an accurate fiow of the melted material'is produced and a web of the desired thinness produced. After one or two severing operations, the operator becomes adept at forming the thin skin integrally uniting the filaments' Various efi'ects can be produced by changing the angle of severance, as illustrated in Fig. 6.

It will be understood that considerable variation is contemplated in the practice of the process. Instead of confining the fibers within binders, as illustrated, they may be stacked in containers and heat applied either by way of severance or to one end of the fibers as they are supported in aligned relation.

Attractive trimmings are formed readily by the method described. A bundle of fibers may be quickly united to form a tassel or other form of trimming by the application of a heated wire, etc., to form the integrating skin. Rugs, velvets, plushes may be similarly formed. Any suitable backing for these products may be provided by cementing the web, through the use of resilient adhesive or other means directly to a backing sheet of fabric or other desired material.

The degree of heat may, of course, be varied in a number of ways by the character of the resistance wire, its diameter, etc. Further, the rate of speed at which the fiber bundle is moved along the wire, the pressure with which it is held to the wire, are also factors which should vary depending upon the type of material used. The thickness of the resulting base sheet or web and its pliability are affected directly by the speed at which the fiber bundle is moved along the wire. Instead of having the bundle move along the hot wire, it will be understood that the hot wire itself may be reciprocated or otherwise moved to provide the desired control.

In some cases, the process is most advantageously conducted in the absence of oxygen (as with nylon). Suitable attendant conditions will be, of course, employed as needed. For example, with nylon, for instance, the process is improved by a moistening of the fibers with water before processing. Further, the utilization of such agents as will promote plastic flow, such as solvents, plasticizers, etc., may be employed.

The resulting product is extremely sturdy, highly flexible, while at the same time providing soft and attractive filaments which are integrally connected to the web. The product may be readily washed. The flexible qualities of the web enable it to be used where peltries and fabrics have heretofore been employed. Further, the product is formed expeditiously and at slight cost and by methods which lend themselves readily to simple machines for carrying through the operatlon' steps automatically.

While in the foregoing specification, I have set forth single embodiments of the invention in great detail for the purpose of illustrating the invention, it will be understood that such details may be varied widely by those skilled in the art without departing from the spirit of my invention.

I claim:

1. In a process for forming a piled web from a bundle of thermoplastic filaments by heating said filaments to fusion temperature through contact with a hot wire, the step of providing relative motion between the bundle and the wire longitudinally of the wire while the wire is passing transversely through the bundle.

2. In a process for forming a piled web from a bundle of thermoplastic filaments by heating said filaments to fusion temperature through contact 7 6 with a hot wire, the steps of applying the fiber bundle to the wire by applying force at an oblique angle to the axis of the filaments and providing relative motion between the bundle and the wire longitudinally of the wire while the wire is passing transversely through the bundle.

3. In a process for forming a piled web from a bundle of polyamide plastic filaments by heating said filaments to fusion temperature through contact with a hot wire, the step of providing relative motion between the bundle and the wire longitudinally of the wire while the wire is passing transversely through the bundle.

4. In a process for forming a piled web from a bundle of polyamide plastic filaments by heating. said filaments to fusion temperature through contact with a hot wire, the steps of applying the fiber bundle to the wire byapplyingforce at an oblique angle to the axis of the filaments and providing relative motion' between the bundle and the wire longitudinally of the wire while the wire is passing transversely through the bundle.

5. In a process for forming a piled web from a bundle of polyvinylidene chloride plastic filaments byheating said filaments to fusion temperature through contact with a hot wire, the step of providing relative motion between the bundle and the wire longitudinally of the wire while the wire is passing transversely through the bundle.

6. In a process for forming a piled web from a bundle of polyvinylidene chloride plastic filaments by heating said filaments to fusion temperature through contact with a hot wire, the steps of applying the fiber bundle to the wire by applyin force at an oblique angle to the axis of the filaments and providing relative motion between the bundle and the wire longitudinally of the wire while the wire is passing transversely through the bundle.

' HYMAN GAIBEL.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Dodge Mar. 23, 1948 

